Toolpack for manufacturing containers

Abstract

A precision high cyclic rate metal forming toolpack is disclosed for ironing processes used to produce can or other bodies and preforms of ultra-high precision. An example of the toolpack provides improved centering, dampening and force attenuation response. In an example, the toolpack may be implemented with integrated feedback communication and sensoring. An example of the toolpack also provides unified coolant distribution, including enhanced locational intelligence of infinitely variable tooling positions. An example of the toolpack also provides improved axial and longitudinal articulation for improved tool tracking and floatation. The toolpack may enable improved product quality, throughput, manufacturing efficiency, reduced costs, and reduced labor.

The invention claimed is: 
     
       1. A toolpack for manufacturing containers, the toolpack having a plurality of individual modules and a control system, each module comprising:
 a module ring; 
 a dampening structure within the module ring, the dampening structure comprising a contiguous dampening mechanism comprising at least one pressurized chamber; 
 a die carrier and an ironing die within the dampening structure; 
 a coolant structure integrated within the die carrier; and 
 one or more sensors configured to produce a signal indicative of a parameter; 
 wherein the control system is coupled with the dampening structure, and wherein the control system is configured to receive the signal from the one or more sensors and adjust the at least one pressurized chamber based on the signal. 
 
     
     
       2. The toolpack of  claim 1 , wherein the adjustment of the at least one pressurized chamber is configured to centralize articulation forces and attenuation of the ironing die. 
     
     
       3. The toolpack of  claim 1 , wherein the dampening structure is performs radial articulation and lateral force intensity attenuation through adjustment of the at least one pressurized chamber. 
     
     
       4. The toolpack of  claim 1 , wherein adjustment of the at least one pressurized chamber provides adjustable force intensity attenuation. 
     
     
       5. The toolpack of  claim 1 , wherein the dampening structure provides an axial and lateral dampening force. 
     
     
       6. The toolpack of  claim 1 , wherein the at least one pressurized chamber comprises a plurality of various geometric chambers in geometric configurations selected based on a desired force intensity, attenuation and service longevity of the dampening structure. 
     
     
       7. The toolpack of  claim 1 , wherein the at least one pressurized chamber further comprises a plurality of geometric chambers located at different locations around or within the contiguous dampening mechanism. 
     
     
       8. The toolpack of  claim 1 , wherein the contiguous dampening mechanism is actively energized. 
     
     
       9. The toolpack of  claim 1 , wherein the contiguous dampening mechanism is passively energized. 
     
     
       10. The toolpack of  claim 1 , wherein the parameter is one or more of pressure, location, temperature, or vibration. 
     
     
       11. The toolpack of  claim 1 , wherein the at least one pressurized chamber is adjustable by fluid, gels, or electrical/magnetic excitation based on the signal from the one or more sensors. 
     
     
       12. The toolpack of  claim 1 , wherein the adjustment of the at least one pressurized chamber produces responsive articulation in both a radial axis and a lateral axis. 
     
     
       13. The toolpack of  claim 1 , wherein the control system is further configured to adjust the coolant structure based on movement of the ironing die. 
     
     
       14. The toolpack of  claim 1 , wherein the control system is configured to adjust the at least one pressurized chamber within the contiguous dampening mechanism on the basis of a desired product quality being produced by the toolpack. 
     
     
       15. The toolpack of  claim 1 , wherein the control system is configured to receive external sensor readings from the die carrier including monitoring of tool positional energy, intensity and speed of dampening response mechanics. 
     
     
       16. The toolpack of  claim 1 , wherein the contiguous dampening mechanism is a molded structure. 
     
     
       17. The tool pack of  claim 16 , wherein the molded structure comprises urethane or Viton. 
     
     
       18. A toolpack for manufacturing containers, the toolpack having a module comprising:
 a module ring; 
 a dampening structure within the module ring, the dampening structure comprising a contiguous dampening mechanism comprising a plurality of pressurized chambers; 
 a die carrier and an ironing die within the dampening structure, wherein the contiguous dampening mechanism surrounds the die carrier; 
 one or more sensors configured to produce a signal indicative of a parameter; and 
 a control system coupled with the dampening structure, wherein the control system is configured to receive the signal from the one or more sensors and adjust the pressurized chambers based on the signal to provide variable dampening rates. 
 
     
     
       19. The toolpack of  claim 18 , further comprising a coolant structure comprising a coolant nozzle configured to move in unison with the ironing die. 
     
     
       20. The toolpack of  claim 18 , wherein the plurality of pressurized chambers are spaced from each other and have different shapes to provide regionalized force intensity profiles in relation to a Cartesian orientation within the toolpack.